Spinning



April 22, 1969 Filed Sept 15. 19s? N. E. KLEIN SIINNING rm-a- NORMAN E. KL'E'IN INVENTOR,

April 22, 1969 N. E. KLEIN SPINNING Flld 15. 1967 .5 l of Sheet j INVENTOR.

NORMAN 'E .KLEIN ATTORNEY United States Patent "ice U.S. Cl. 57-58.49 28 Claims ABSTRACT OF THE DISCLOSURE The method and apparatus is directed to open end spinning of yarn continuously from sliver or roving'by disintegrating the sliver or roving, recombining the sliver or roving and spinning the recombined sliver or roving in a two-for-one spinning arrangement.

Open end spinning systems per se are well known and have been known for a number of years, however, no commercially successful system is currently in common use by a large number of textile producers. In recent years a number of patents and articles relating to open end spinning systems have become available to the public but all of these systems are in the one-for-one class of spinning equipment. These systems, although they present some degree of mechanical feasibility, appear to have drawbacks which at present do not make them competitive to spinning systems currently in use. Generally, the yarn strength of known open end one-for-one spinning systems is at least lower than that for yarn of equivalent size made on a ring and traveler system. Further, these systems require higher twist than ring and traveler systems in order to affect pick up action in the spinning operation and to provide sufficient interfiber function-force action to provide sufficient yarn strength. Also, it has been found that spin range (count size) of yarns that can be made on such systems is limited.

It is therefore an object of the invention to provide a method and apparatus which will produce yarn on an open end spinning system which is competitive with yarn produced on conventional systems.

A second object of the invention is to duplicate as near as possible the draft-feed roll twist-into-nip spinning action used in conventional spinning operations.

A third object of the invention is to combine the principles of open end fiber transfer, conventional drafting and two-for-one twisting to form and open end spinning system resulting in a yarn which has strength and twist characteristics similar to yarn produced by the convention-al ring and traveler.

Another object of the invention is to provide a new and novel spinning system which increases the production of yarn in comparison to conventional spinning for a given amount of plant floor space.

A further object of the invention is to provide a drafting-straightening-tensioning action on a transferred-reconstituted fiber ribbon prior to spinning.

A still further object of the invention is to provide a compact open end spinning system which employes a two-for-one twisting arrangement in which the drafting system is located within the generated balloon.

Other objects and advantages of the invention will become readily apparent as the specification proceeds to describe the invention with reference to the accompanying drawings, in which:

FIGURE 1 is an overall schematic view of the new and improved open end spinning system;

FIGURE 2 is a cross sectional view of the spindle shown in FIGURE 1;

Patented Apr. 22, 1969 FIGURE 3 is a view generally taken on line 3-3 of FIGURE 2 with parts removed to show the top of the fiber collection and transfer ring housing;

FIGURE 4 is a view taken on line 4-4 of FIGURE 2 showing the bottom of the fiber collection and transfer ring housing;

FIGURE 5 is a cross-sectional view on line 5-5 of FIGURE 6 showing a portion of the drafting system;

FIGURE 6 is a view taken on line 6-6 of FIGURE 2 showing another view of the drafting system;

FIGURE 7 is a view taken on line 77 of FIGURE 2 showing the top of the drafting system, and

FIGURE 8 is a side view With parts removed to show the transfer belt system to transfer fibers from the rotor to the drafting system.

Looking now to FIGURE 1, the overall new and novel open end spinning system is schematically illustrated. Sliver 10 is supplied to the bottom of open end spinning spindle 12 from the sliver can 14 through a conventional fiber drafting system 16 which incorporates at least two stages of drafting. In the spindle 12 the sliver 10 is drafted down so that substantially discrete fibers are fed to the spindle, transferred to the stabilizing platform, reconstituted, drafted and emerge from the flyer portion of the spindle 12 as partially-twisted yarn. The yarn is then pulled through pig tail guide 18 and forms the balloon 20 outwardly around the spindle 12 wherein the rest of the predetermined twist is imparted thereto. Then it travels through another pig tail guide 22 to the take-up package 23 driven by surface drive roller 24. In conventional fashion a traversing yarn guide 26 is employed to build the proper layer of yarn on the package.

FIGURES 2-7 illustrate in detail the preferred spindle arrangement for the spindle 12 shown in FIGURE 2. Rigidly mounted adjacent the nip of drafting rolls 28 is a tube 30 with an internal venturi shape with the internal diameter thereof decreasing from the entrance end adjacent the rolls 28 to the exit end 31 adjacent the opening 32 into the rotor 50. Tube 30 is supported by a support member 34 which is attached to spindle frame 36 (FIG. 1) rigidly secured to a spindle support (not shown). Surrounding the tube 30 and slightly spaced thereform is a concentric spindle member 38 rotatably supported by upper and lower bearings 40 and 42, respectively, which have the outer race thereof rigidly supported in the sup port member 34. Attached to the lower end of hollow shaft 38 is a pulley 44, fastened thereto by any suitable means such as set screw 46, and which is engaged by spindle drive belt 48 to drive the spindle (FIGURE 1) from a source (not shown).

Secured to upper end of hollow shaft member 38 by suitable means, such as welding or shrink fitting, is the rotor 50 to which is attached at the bottom thereof a fan hub 52 supporting a plurality of fan blades 54 for reasons hereinafter explained. Rigidly secured to the spindle member 38 and rotating therewith is -a hollow spindle member extension 56 which provides non-rotational positioningsupport for upper platform structure 58 through a pair of bearings 50 and 62. Formed on the top of the spindle extension 56 are a plurality of gear teeth 64 which engage and drive the gear 66.

Concentrically surrounding the rotor 59 is the lower platform member 68 connected to the upper platform member 58 by suitable means such as screws 70. The lower and upper platform members with other attached parts are stabilized against rotation by eccentric weighing, however, other means, such as magnetic attraction or planetary, may be employed.

Rotatably secured by the lower platform member 68 through a suitable bearing 72 is the fiber collection and transfer ring 74 driven at a slow speed, such as five r.p.m.,

by the engagement of gear 76 with the ring gear 78 integrally connected to the outer periphery of the fiber collection and transfer ring 74. Fiber collection and transfer ring 74 has a plurality of holes 79 therein extending completely around the circumference thereof and cooperating continuously with the radial opening 80 in the rotor 50, and periodically with the opening 82 in the lower platform member 68, to receive discrete or wisps of fiber from the opening 80 in the rotor 50, build up such fibers into a ribbon and transfer them to fiber transfer-drafting unit 84 shown in detail in FIGURE 8.

As will be explained hereinafter a ribbon of reconstituted fibers will be picked olf the upper surface of the transfer ring 74 and delivered to the nip of the transfer belts 86 and 88. Transfer belts 86 and 88 are driven in the direction indicated by the rolls 90 and 92, respectively. To vary the tension of the belts 86 and 8-8 an adjustable belt guide member 94 is secured adjacent the rolls. Located within the confines of the belts between the upper reversal zone of the belts and the rolls is belt guiding and cleaning member 96 such as that disclosed in US. Patent 3,132,384, which has a concave surface 98 engaging the surface of the rolls to clean off accumulated lint and an integral nose reversal portion 100 to guide the reversal of the belts 86 and 88.

Drive rolls 90 and 92 generally perform the function of the middle drafting rolls of a conventional fiber drafting system with the belt portions 102 and 104 of the transfer belts 86 and 88 acting as drafting aprons similar to that found in double apron drafting systems. The belt guiding and cleaning members 96 each have a surface 106 facing the fiber engaging run of the belt portion 102 and 104 to guide the belt portions 102 and 104 to prevent buckling of the belts in the drafting area and to maintain control of the fibers being drafted.

The roll and belt system, generally designated 108, corresponds to the front drafting rolls of a conventional drafting system. As in conventional drafting systems the rolls 110, 112 and 114 are driven at a speed greater than the rolls 90 and 92 to provide the desired degree of drafting of the fibers in the zone between the nip of rolls 90 and 92 and the nip of rolls 110 to 112. The belt aprons 116 travels in an endless path around rolls 110 and 114 to transfer filler from the nip of rolls 110 and 112 to the nip of rolls 12 and 14 thereby providing an elongated nip zone wherein control of the fibers is enhanced in their redirection toward spindle 56.

Preferably, roll 112, positioned to act as the bottom delivery-drive roll on a conventional spinning frame, is substantially hollow with a plurality of openings 118 therein which pass through the roll 112 and are in communication with the hollow interior of the roll to provide better drafting and control of the fibers being drafted in the manner disclosed in US. Patent 3,296,664. The openings 11 8 are preferably elongated in the direction of the axis of the roll and lie around the periphery of the roll 112 in a relatively narrow area. Mounted closely adjacent the bottom of perforated roll 112 is a suction manifold 120 (FIGURES and 6) which communicates via suction conduit 121 with a suction chamber 122 defined by a housing member 124 mounted on the upper platform member 58. Upper platform member 58 has openings 126 therein to provide communication between suction chamber 122 and fan blades 51 forming integral part of upper side of rotor 50.

The main drive to the spindle is from a source (not shown) through the drive belt 48 (FIGURES l and 2). Belt 48 drives the shaft members 38 and 56 which in turn engages and drives the gear 66. Gear 66 is directly connected to gear 128 via shaft 130 and drives the perforated roll 112 (FIGURES 2 and 5-7) through a suitable gear train which includes helical gears 128, 132 and 13 4.

FIGURES 2, 6, 7 and 8 show the gear train which drives the rolls 90 and 92 to cause the transfer belt systern 84 to operate. Gear 134 which drives the perforated roll 112 is connected to one end of shaft 136 while another gear 138 is connected to the other end of the shaft 136 to provide the motive force for the rolls and 92 through gears 140 and 142. Gear 142 in turn is connected to a shaft 144 (FIGURE 8) which supports left and right hand helical gears 146 and 148 that engage left and right hand helical gears 93 and 95, respectively, mounted on shafts 152 and 153 to drive respectively on the rolls 92 and 90 at the desired speed.

Then to drive the fiber collection and transfer ring 74 at a peripheral speed slightly lower than transfer belts 86 and 88 a gear train is operably employed to engage the ring gear 78 on the periphery of the transfer ring 74. To accomplish this, change gear is proportioned in relation to ring gear 78 and is secured to the end of shaft 152 which supports the roll 92 and through idler gears 154 and 76 drives the ring gear 78. So it can readily be seen that all the moving elements of the system are driven from a single drive source.

Operation Looking now in particular to the fiber flow, FIGURE 2 shows fiber F in substantially discrete form being delivered from the nip of the front rolls 28 of the drafting system into the elongated venturi shaped tube 30. The fiber F from the rolls 28 is either single fibers or small groups or wisps of fibers. An air flow is created up the tube 30 by the centrifugal force action of the rotor 50 and the cooperating action of the fan blades 54 which move the fibers F up the tube into the opening 32 leading into the radial passage 80 for the rotor 50. It is desired that the fibers F remain oriented and to this effect, as pointed out, the tube 30 is venturi shaped so that as the fiber F travels up the tube 30 the lead end of the fiber will, due to its position in faster moving air than the tail, be pulled forward with greater force than the trailing end of the fiber to cause the fibers F from the nip of rolls to remain in axially oriented-discrete form and not become entangled due to unbalanced vortical forces acting on the fibers in the passage to the opening r32.

As discussed briefly, the rotor 50 is driven directly from the drive source at a speed of 20,000 rpm. or higher while the collection and transfer ring 74 through suitable step down gears 150, 154 and 76 is driven at a much slower speed on the order of 5 r.p.m. which means that the rotor 50 makes about 4000 r.p.m. for each r.p.m. of the ring 74. Fibers F entering the opening 32 remain oriented head end first and continue through the radial passage 80 of the rotor in this manner through the combined action of two forces (1) that created by the gradient velocity increase of air flow at the head end of the fiber versus the tail end due to further narrowing of the passageway up to the periphery of the rotor and (2) the very much greater centrifugal force action on an'element of fiber at an outer position in relation to an element of fiber at a point less removed from the axis of rotation. This results in a powerful straightening action on each fiber.

As a fiber head emerges from the rotor radial opening 80, it encounters slower peripherally moving air than the surface speed of the rotor. A drag on the head of the fiber aids in pulling the fiber from the rotor as said fiber is wiped into positon on the surface of circular collector disc 74. Air drawn through multiple openings 79 then holds fibers thus received from the rotor in place.

Since fiber discharge from the rotor can occur at any random position of the rotor the radial deposition density over any unit of are around the throw disc will tend towards uniformity, since any one are segment has the same exposure time as any other segment to receive fibers. Moreover if there should be any non-uniformity in constructing either disc 74 or upper plate 58 forming passage to openings 79 the rotation of disc 74 distributes any centralized action over the whole disc. The density of fibers at any point around the collection ring of holes 79 will then be in proportion to the time of exposure to the rotor. Fiber density will then be graduated; heaviest at the point of pick up (at convergence of belts 88 and 86 near the surface of collector disc 74) down to zero at start of deposition on a cleared surface. We have achieved, at the same time, a linear deposition-storage device that tends to iron out short term non-uniformity.

As discussed briefly before, the fan blades 54 pull air down through the openings 79 causing fibers to deposit onto surface of transfer ring 74, wherein the deposition attitude of each fiber is not exactly the same as the previous. This results in a substantial degree of cross lay component which improves the fiber migration factor, without which a staple yarn would have little strength. Fibers have now been deposited in a C (partial ring) shaped path, the density of which increases as the forward end approaches the nip of the transfer belts 86 and 88 positioned over the opening 82 in the lower platform member 68, When the perforations 79 of the collection and transfer ring pass over the opening 82 the suction pressure created by the fan blades 54 is relieved thereby relieving the force on the ribbon of fibers at that point allowing them to move towards the nip of transfer belts 86 and 88 and move therebetween. To further enhance this operation a deflection member 156 may be attached to the bottom of the lower platform member 68 to direct air from the fan blades up theopening 82 and through the openings 79 to urge the ribbon of fibers towards the transfer belts 86 and 88. In the preferred form of the invention the gear ratio between the gear drive for the rolls 90 and 92 and the ring gear 78 is such that the linear speed of the transfer belt 86 and 88 is slightly greater than the linear speed of the transfer of fibers from the ring 74 providing a slight drafting of the fiber ribbon from the ring 74 which is approximately equivalent to a break draft in a convention-a1 drafting system.

Looking now in particular to FIGURES 2, 5 and 8 it can be seen that the ribbon of fibers between the transfer belts is delievered to the nip of rolls 90 and 92 which not only drive the transfer belts 86 and 88 but also act as drafting rolls in the manner conventionally seen in the use of middle drafting rolls of a conventional short apron three roll drafting system. Consequently, a gear ratio is selected which will drive the rolls 90 and 92 at a speed considerably less than the speed of the rolls 110, 112, and 114 to accomplish a draft of the fiber of at least two to one and preferably of the order of ten to 1. The drafting of the fibers takes place between the nip of the rolls 90 and 92 and the nip of the rolls 110 and 112 in the delivery roll assembly. The endless belt 116 performs the function of elongating the nip area from point 158 to point 160 to change the direction of travel of the fiber ribbon so that twist in the yarn, generated by spindle 56 can run back into nip 160.

As previously discussed it is preferred that roll 112 be of the perforated roll type disclosed in US Patent 3,296,664 to better control fibers when operating at high front roll speeds. In this case speed may be as high as 1000 r.p.m, or more. The perforated front roll 112 reduces fanning out and loss of fibers and at the same time provides a degree of cleaning action.

From the nip 160 of the rolls 112 and 114 the operation of the spindle approaches that of a conventional twofor-one twister in that the drafted-twisted fiber is pulled down into a passage 162 in the hollow spindle member extension 56 into the passage 164 which runs through a corner of shaft member 38 and through rotor 50. The drafted yarn Y will be held against the wall at some point either in the passage 162 or passage 164 and thereby have one turn of twist imparted thereto due to the rotation of the spindle. As in conventional systems this twist will run back to the nip of the rolls 112 and 114.

The partially twisted yarn Y then passes through an opening 166 in the fan hub 52, through pig tail guide 18 to form balloon 20 wherein the rest of the twist is imparted thereto and then through guide 22 to the takeup 23 roll as previously explained.

In view of the above disclosure it can be seen that a high speed open and spinning system has been disclosed which successfully combines spinning and winding operations to allow the direct production of large size yarn packages, as large as 5 or 10 pounds, which cannot currently be accomplished on the conventional ring and traveler system. An open end spinning system has been disclosed which will allow further drafting or parallelizing of the fibers after they have been transferred and reconstituted and prior to take-up which therefore provides yarn of characteristics very similar to that obtained on the conventional ring and traveler system.

That which is claimed is:

1. A method to produce yarn from staple fibers comprising the steps of: disintegrating a sliver or roving into substantially discrete fibers, reconstituting said fibers into a fiber ribbon, forming said ribbon into a rotating balloon, putting at least two turns of twist in said fiber ribbon for each rotation of said balloon and taking up the twisted fiber ribbon on a yarn package.

2. The method of claim 1 wherein said fiber ribbon is drafted prior to rotation in said balloon 3. A method of producing yarn comprising the steps of: disintegrating a sliver or roving into substantially discrete fibers, transferring said fibers onto a substantially stationary platform, forming a fiber ribbon by collecting and reconstituting said fibers, feeding said fibers axially axially outward from said platform and generating a yarn balloon around said platform to twist said fiber ribbon and taking up the twisted fiber .ribbon on a yarn package.

4. The method of claim 3 where said fiber ribbon is drafted prior to being fed axially outward.

5. The method of claim 3 wherein said method is continuous.

6. The method of claim 4 wherein said method is continuous.

7. The method of claim 3 wherein transferring of fibers is discontinuous.

8. Apparatus to produce yarn from staple fiber comprising: a disintegratiomfiber transfer-recollection means, means to supply fibers to said disintegration-fiber transferrecollection means, a twofor-one twisting system, means to convey fibers from a disintegration-fiber transfer-recollection means to said two-for-one twisting system and take-up means taking up yarn from said two-forone twisting system.

9. The structure of claim 8 wherein said fiber conveying means includes a drafting system to draft fibers prior to transfer into said two-for-one twisting system.

10. The structure of claim 9 wherein said drafting system includes a hollow perforated drafting roll, means providing a negative pressure, said hollow perforated drafting roll being connected to said negative pressure source to apply suction pressure to the fibers being drafted.

11. The structure of claim 10 wherein said negative pressure source is generated within said two-for-one twisting system.

12. The structure of claim 8 wherein said two-for-one twisting system generates a rotating yarn balloon, a portion of said disintegration-fiber transfer-recollection means being located within the confines: of the generated balloon.

13. The structure of claim 12 wherein said fiber conveying means includes a drafting system to draft said fiber ribbon prior to transfer into said two-for-one twisting system.

14. The structure of claim 13 wherein said drafting system is supported within the confines of said generated balloon.

15. Apparatus to produce yarn from staple fiber comprising: a substantially hollow spindle, means rotatably supporting said spindle, a rotor supported on said spindle, said rotor having a radial passage therein communicating with the hollow interim of said hollow spindle, a collection ring rotatably supported adjacent said rotor and receiving fiber from said rotor radial passage, a drafting system mounted above the hollow interim of said spindle, means mounted in said spindle to transfer fibers from said collection ring to said drafting system and means to generate a yarn balloon around said spindle, said rotor, said collection ring and said drafting system.

16. The structure of claim 15 wherein said drafting system includes a hollow perforated drafting roll, said hollow perforated drafting roll being connected to a negative pressure source to apply suction pressure to the fibers being drafted.

17. The structure of claim 16 wherein means are provided on said spindle to generate said suction pressure.

18. The structure of claim 15 wherein said collection ring has a plurality of apertures therein around the periphery thereof, said fibers from said rotor being deposited thereon, and means connected to said spindle to pull air through said apertures to help retain said fibers in said collection ring.

19. The structure of claim 18 wherein said means to pull air through said apertures includes a fan means connected to said rotor.

20. The structure of claim 18 wherein said spindle includes means to momentarily stop the evacuation of air through said apertures to allow said fiber transfer means to pick up fibers from said collection ring.

21. Apparatus to produce yarn from staple fibers comprising: a substantially hollow rotatably supported spindle, a rotor connected to said spindle and rotating therewith, said rotor having a radial passage therein in communication with hollow interior of said spindle, a collection ring rotatably supported in said spindle adjacent the exit of said radial passage, said collection ring having a plurality of apertures therethrough around the periphery thereof to receive fibers thereon from said radial passage, a drafting system supported above the hollow interior of said spindle, transfer belt means supported between said collector ring and said drafting system to transfer fibers from said collection ring and said drafting system and means to pass drafted fibers from said drafting system through said hollow spindle and generate a balloon of yarn around said spindle.

22. The structure of claim 21 wherein said spindle includes an elongated hollow fiber entrance tube fixed therein in flow relation to said radial passage in said rotor, said tube having an internal venturi with the smallest diameter being adjacent the entrance to said radial passage.

23. The structure of claim 22 wherein said spindle includes a means to pull air through said apertures in said collection ring to retain fiber deposited on said ring from said radial passage in said rotor.

24. The structure of claim 23 wherein said drafting system includes a hollow perforated drafting roll, said means pulling air through apertures in said collection ring also being in communication with said hollow drafting roll to pull air through said perforated drafting roll to apply suction pressure to the fibers being drafted.

25. The combination with a two-for-one fiber strand producing apparatus of the kind in which the strand generates a ballooning figure of revolution during the twisting thereof of a drafting system located wholly within the figures of revolution of the strand, said drafting system having a hollow perforated drafting roll therein in communication with a suction source also located wholly within the figure of revolution of the strand.

26. The combination with a two-for-one fiber strand twisting apparatus of the kind in which the strand generates a ballooning figure of revolution during the twisting thereof, of a yarn reconstituting system within the figure of revolution of the strand supplying fiber to the two-for-one twisting apparatus.

27. The combination of claim 26 which also includes a drafting system within the figure of revolution receiving a ribbon of fibers from said yarn reconstituting a system.

28. Apparatus to produce yarn from staple fiber comprising: means to generate a rotating yarn balloon, a sub stantially stationary platform within the confines of said yarn balloon, means synchronized with the rotation of said yarn balloon to supply substantially discrete fibers to said platform and form a ribbon of fibers therein, means to transfer said ribbon of fibers to said yarn balloon generating means and means to take up the yarn from said balloon.

References Cited UNITED STATES PATENTS 2,869,315 l/l959 Klein 57-36 3,007,299 11/1961 Starnes 5736 3,119,223 l/1964 Meimberg 5758.95 XR 3,343,360 9/1967 Brown 5758.95 XR 3,360,917 1/1968 Kubovy et a1 57--58.95

STANLEY N. GILREATH, Primary Examiner.

WERNER H SCHROEDER, Assistant Examiner.

US. Cl. X.R.

U.S. DEPARTMENT OF COMMERCE PATENT OFFICE Washington, D.C. 20231 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,439,486 April 22 1969 Norman E. Klein It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 50, "to form and open" should read to form an open Column 2, line 60, "50" should read 60 line 69, before the comma insert gearing Column 3, line 45, "12" and "14" should read 112 and 114 Column 5, line 42, "delievered" should read delivered Column 6, line 33, "axially" should be canceled. Column 8, line 15, "figures" should read figure Signed and sealed this 51st day of March 1970.

(SEAL) Attest:

Edward M. Fletcher, Jr. E.

Attesting Officer Commissioner of Patents 

